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Characterization of Coal Combustion Residues from Electric Utilities Using Wet Scrubbers for Multi-Pollutant Control EPA/600/R-08/077 July 2008

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Characterization of Coal Combustion Residues from Electric Utilities Using Wet Scrubbers for Multi-Pollutant Control EPA/600/R-08/077 July 2008 EPA-600/R-08/077 July 2008 Characterization of Coal Combustion Residues from Electric Utilities Using Wet Scrubbers for Multi-Pollutant Control EPA/600/R-08/077 July 2008 Characterization of Coal Combustion Residues from Electric Utilities Using Wet Scrubbers for Multi-Pollutant Control F. Sanchez1, D. Kosson1, R. Keeney2, R. Delapp1, L. Turner3, and P. Kariher2 1Vanderbilt University Department of Civil and Environmental Engineering Nashville, TN 37235 2ARCADIS 4915 Prospectus Drive, Suite F Durham, NC 27713 3Turner Technology Nashville, TN 37235 Category III / Applied Research Contract No. EP-C-04-023 Work Assignment No. 4-26 Project No. RN990234.0026 U.S. Environmental Protection Agency Office of Research and Development National Risk Management Research Laboratory Air Pollution Prevention and Control Division Cincinnati, Ohio Notice The U.S. Environmental Protection Agency (EPA) through its Office of Research and Development funded the research described here under Work Assignment No. 4-26 of Contract Number EP-C-04-023 to Vanderbilt University. It has been subjected to the Agency’s peer and administrative review and has been cleared for publicationas an EPA document. Reference herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise, does not necessarily constitute or imply its endorsement or recommendation. The views and opinions of authors expressed herein do not necessarily state or reflect those of EPA or any agency thereof. ii Foreword The U.S. Environmental Protection Agency (EPA) is charged by Congress with protecting the Nation's land, air, and water resources. Under a mandate of national environmental laws, the Agency strives to formulate and implement actions leading to a compatible balance between human activities and the ability of natural systems to support and nurture life. To meet this mandate, EPA's research program is providing data and technical support for solving environmental problems today and building a science knowledge base necessary to manage our ecological resources wisely, understand how pollutants affect our health, and prevent or reduce environmental risks in the future. The National Risk Management Research Laboratory (NRMRL) is the Agency's center for investigation of technological and management approaches for preventing and reducing risks from pollution that threaten human health and the environment. The focus of the Laboratory's research program is on methods and their cost-effectiveness for prevention and control of pollution to air, land, water, and subsurface resources; protection of water quality in public water systems; remediation of contaminated sites, sediments and ground water; prevention and control of indoor air pollution; and restoration of ecosystems. NRMRL collaborates with both public and private sector partners to foster technologies that reduce the cost of compliance and to anticipate emerging problems. NRMRL's research provides solutions to environmental problems by: developing and promoting technologies that protect and improve the environment; advancing scientific and engineering information to support regulatory and policy decisions; and providing the technical support and information transfer to ensure implementation of environmental regulations and strategies at the national, state, and community levels. This publication has been produced as part of the Laboratory's strategic long-term research plan. It is published and made available by EPA's Office of Research and Development to assist the user community and to link researchers with their clients. Sally Gutierrez, Director National Risk Management Research Laboratory iii Characterization of Coal Combustion Residues II ACKNOWLEDGMENTS Extensive input on the research program design was provided by G. Helms, U.S. EPA, Office of Solid Waste (Washington, D.C.). Laboratory testing described herein was carried out by ARCADIS with technical support from Vanderbilt University. R. Delapp was responsible for the chemical analyses carried out at Vanderbilt University. Technical assistance also was provided by A. Garrabrants. K. Ladwig and the Electric Power Research Institute (EPRI) are gratefully acknowledged for assistance in obtaining coal combustion residue samples and providing information from the EPRI database on coal combustion residues. S. Thorneloe is the U.S. EPA project officer for this research. Note: R. Keeney substantially participated in the work reported here and the preparation of this report but left employment of ARCADIS prior to the completion of this study and report. iv Characterization of Coal Combustion Residues II TABLE OF CONTENTS Acknowledgments.......................................................................................................................... iv Abstract........................................................................................................................................... v Glossary of terms ........................................................................................................................... vi Executive Summary....................................................................................................................... ix Table of Contents.......................................................................................................................... xii List of Tables ................................................................................................................................ xv List of Figures.............................................................................................................................. xvi 1. Introduction................................................................................................................................. 1 1.1. Regulatory Context ...............................................................................................................6 1.1.1. Waste Management....................................................................................................... 6 1.1.2. Air Pollution Control ....................................................................................................6 1.2. Configurations of U.S. Coal Fired Power Plants and Multi-pollutant Control Technologies................................................................................................................................7 1.2.1. Current Air Pollution Control Technologies................................................................. 8 1.2.2. Wet Scrubbers, NOx Controls and Multi-pollutant Controls ..................................... 11 1.3. Coal Combustion Residues.................................................................................................12 1.4. Residue Management Practices ..........................................................................................13 1.4.1. Beneficial Use............................................................................................................. 13 1.4.2. Land Disposal ............................................................................................................. 14 1.5. Leaching Protocol ...............................................................................................................16 2. Materials and Methods.............................................................................................................. 20 2.1. CCR Materials for Evaluation ............................................................................................20 2.1.1. Facilities Using Inhibited or Natural Oxidation of Scrubber Residues (Producing Scrubber Sludge or Fixated Scrubber Sludge)...................................................................... 24 2.1.1.1. Facility A (Natural Oxidation and SNCR)........................................................... 24 2.1.1.2. Facility B (Natural Oxidation and SCR).............................................................. 24 2.1.1.3. Facility K (Natural Oxidation and SCR) ............................................................. 25 2.1.1.4. Facility M (Inhibited Oxidation and SCR) .......................................................... 25 2.1.2. Facilities Using Forced Oxidation of Scrubber Residues (Producing FGD Gypsum) 26 2.1.2.1. Facility N (Forced Oxidation).............................................................................. 26 2.1.2.2. Facility O (Forced Oxidation and SCR) .............................................................. 26 2.1.2.3. Facility P (Forced Oxidation and SCR and SNCR)............................................. 26 2.1.2.4. Facility Q (Forced Oxidation and SCR) .............................................................. 27 v Characterization of Coal Cumbustion Residues II 2.2. Leaching Assessment Protocols..........................................................................................27 2.2.1. Alkalinity, Solubility and Release as a Function of pH (SR002.1) ............................ 27 2.2.2. Solubility and Release as a Function of LS Ratio (SR003.1)..................................... 28 2.3. Analytical Methods.............................................................................................................28 2.3.1. Surface Area and Pore Size Distribution .................................................................... 28 2.3.2. pH and Conductivity................................................................................................... 28 2.3.3.
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